Kemppi KMS 400 AS User Manual

FastMig

KMS 400 AS

Operating manual

EN

OPERATING MANUAL

English

EN

CONTENTS

1. Preface ...................................................................................................................................... 3

1.1 General ....................................................................................................................................... 3

1.2 About FastMig KMS AS product........................................................................................ 3

2. Installation ............................................................................................................................. 4

2.1 Before use .................................................................................................................................. 4

2.2 Machine introduction ........................................................................................................... 5

2.3 Positioning and location of the machine ...................................................................... 5

2.4 Connecting cables ................................................................................................................. 6

2.4.1 Liquid cooled system: FastMig KMS AS + MSF/MXF + FastCool 10 +

ArcFeed ............................................................................................................................. 6

2.4.2 FastMig KMS AS + ArcFeed ............................................................................................. 6

2.5 Connection to the mains supply ...................................................................................... 7

2.6 Welding and earth cables.................................................................................................... 7

2.7 Functions of AS panel ........................................................................................................... 8

2.8 Setup functions ....................................................................................................................... 9

3. Operation control switches and potentiometers ....................................... 9

3.1 Main switch I/O ....................................................................................................................... 9

3.2 Pilot lamps ................................................................................................................................. 9

3.3 Operation of cooling fan ..................................................................................................... 9

4. Basic troubleshooting .................................................................................................10

5. Maintenance ......................................................................................................................11

5.1 Daily maintenance ...............................................................................................................11

5.2 Periodic maintenance .........................................................................................................11

5.3 Service shop maintenance ...............................................................................................11

6. Operation disturbances .............................................................................................12

6.1 Operation of the overload protection ..........................................................................12

6.2 Control fuses ..........................................................................................................................12

6.3 Under- and overvoltages in the mains supply ..........................................................12

6.4 Loss of a phase in the mains supply ..............................................................................12

7. Disposal of the machine ............................................................................................12

8. Ordering numbers .........................................................................................................13

9. Technical data ...................................................................................................................14

2

FastMig KMS 400 AS

1. PREFACE

1.1 General

Congratulations on choosing the FastMig welding equipment. Used correctly, Kemppi
products can signicantly increase the productivity of your welding, and provide years of
economical service.

This operating manual contains important information on the use, maintenance and safety of
your Kemppi product. The technical specications of the equipment can be found at the end
of the manual.

Please read the manual carefully before using the equipment for the rst time. For your
own safety and that of your working environment, pay particular attention to the safety
instructions in the manual.

For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi
dealer, or visit the Kemppi web site at www.kemppi.com.

The specications presented in this manual are subject to change without prior notice.

Important notes

Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow
their instructions.

Disclaimer

While every eort has been made to ensure that the information contained in this guide
is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi
reserves the right to change the specication of the product described at any time without
prior notice. Do not copy, record, reproduce or transmit the contents of this guide without
prior permission from Kemppi.

EN

1.2 About FastMig KMS AS product

FastMig KMS 400 AS is CC (constant current) / CV (constant voltage) power source designed
for demanding professional use. It is suitable for MMA and MIG welding in DC.

FastMig KMS 400 AS is compatible with MSF, MXF and ArcFeed wire feeders.

© Kemppi Oy / 1515

3

EN

2. INSTALLATION

2.1 Before use

The product is packed in specially designed transport cartons. However, before use always
make sure the products have not been damaged during transportation.

Check also that you have received the components you ordered and the instruction manuals
needed, as described in the Quick start guide pack. Product packaging material is recyclable.

NOTE! When moving the welding machine, always lift it from the handle, never pull it from the

welding gun or other cables.

Operating environment

This machine is suitable for both indoor and outdoor use. Always make sure that the air ow to
the machine is unrestricted. The recommended operating temperature range is –20…+40°C.

Please ensure you read the safety instructions concerning operating environments supplied in
this manual.

Distribution network

All regular electrical devices without special circuits generates harmonic currents into the
distribution network. High rates of harmonic current may cause losses and disturbance to
some equipments.

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 4.7 MVA at the interface point between the user’s supply and
the public supply network. It is the responsibility of the installer or user of the equipment
to ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power Ssc greater than or equal
to 4.7 MVA.

4

FastMig KMS 400 AS

2.2 Machine introduction

H11

S11

H12
X14

X12

F11
H11
H12
S11
X11, X13

X11

Fuse for connection for control table 6.3 A delayed
Signal lamp I/O
Warning lamp for thermal protection
Main switch I/O
Welding connection parallel

X13

X12
X14 , X15
01

2.3 Positioning and location of the machine

Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other
impurities to enter the machines cooling air ow. Preferably site the machine above oor level;
for example on a suitable carriage unit.

Notes for positioning the machine

• The surface inclination should not exceed 15 degrees.

• Ensure the free circulation of the cooling air. There must be at least 20 cm of free space in

front of and behind the machine for cooling air to circulate.

• Protect the machine against heavy rain and direct sunshine.

NOTE! The machine should not be operated in the rain as the protection class of the machine,

IP23S, allows for outside preserving and storage only.

01

6,3A

Earth connection
Connection for control cable parallel
Inlet of mains cable

F11

X15

EN

NOTE! Never aim metallic grinding spray/sparks towards the equipment.

© Kemppi Oy / 1515

5

EN

2.4 Connecting cables

NOTE! Always check before use that the interconnecting cable, shielding gas hose, earth return

lead/clamp, and mains cable is in a serviceable condition. Ensure that connectors are correctly
fastened. Lose connectors can impair welding performance and damage connectors.

2.4.1 Liquid cooled system: FastMig KMS AS + MSF/MXF + FastCool 10 +
ArcFeed

GND

6

2.4.2 FastMig KMS AS + ArcFeed

ArcFeed

GND

FastMig KMS 400 AS

2.5 Connection to the mains supply

FastMig power sources are delivered as standard with 5 meters of mains power cable. No
mains plug is tted at the Kemppi factory.

NOTE! If local country based regulations state an alternative power cable is required, the mains

cable must be replaced in conformity with the regulations. Connection and installation of the
mains cable and plug, should only be carried out by a suitably qualied person.

Remove the machine cover plate to enable mounting of a mains cable. FastMig Pulse power
sources can be connected to the mains supply of 400 V 3~ .

If changing the mains cable take into consideration the following:

The cable is entered into the machine through the inlet ring on the rear panel of the machine
and fastened with a cable clamp. The phase conductors of the cable are coupled to connectors
L1, L2 and L3. The earth protection coloured green-yellow is coupled to the marked connector

. If you are using 5-lead cable, do not connect the neutral conductor.

EN

Sizes of the mains cables and fuse ratings for the machine at 100 % duty cycle are specied in
the table below:

Rated voltage Mains voltage range Fuses, slow-blow Connection cable *) mm²

KMS 300 400 V 3~ 360 V – 440 V 20 A 4 x 6.0 S
KMS 400 400 V 3~ 360 V – 440 V 25 A 4 x 6.0 S
KMS 500 400 V 3~ 360 V – 440 V 35 A 4 x 6.0 S

*) In cables of S type there is a protective grounding conductor coloured green-yellow.

2.6 Welding and earth cables

Recommended copper cables with cross-sectional area are as follows:
FastMig KMS 400 AS 70 – 90 mm²
In enclosed table are shown typical load capacities of rubber insulated copper cables, when

ambient temperature is 25 °C and lead temperature is 85 °C.

Cable Duty cycle ED Voltage loss / 10 m

100 % 60 % 30 %
50 mm² 285 A 370 A 520 A 0,35 V / 100 A
70 mm² 355 A 460 A 650 A 0,25 V / 100 A
95 mm² 430 A 560 A 790 A 0,18 V / 100 A

Do not overload welding cables due to voltage losses and heating.
Fasten the earth clamp of the return current cable carefully, preferably direct onto the piece to

be welded. The contact surface of the earth clamp should always be as large as possible.
Clean the fastening surface from paint and rust.

© Kemppi Oy / 1515

7

EN

2.7 Functions of AS panel

ON/OFF button

MIG dynamics / MMA Arc Force adjustment

• When CV is selected, parameter name ’dYn’ and the adjustable value between -9 ... 9 are shown

• When CC/MMA is selected, parameter name ’Arc’ and the adjustable value between -9 ... 9 are

shown

• In MXF mode the dynamics cannot be adjusted with the AS panel and ’--- ---’ is shown. In this case
the adjustment is done through the wire feeder panel

CC/MMA = Constant current mode. Selection with a long press. Selected when operated with ArcFeed
with CC-mode or MMA welding

MXF mode = Use with MSF or MXF feeders
CV mode = Constant Voltage. Selected when operating with ArcFeed CV-mode

Remote selection

• In CC/MMA mode the current can be adjusted with the remote

• In CV mode the voltage can be adjusted with the remote

MIG/MAG welding

FastMig KMS AS is designed for MIG/MAG welding with either the Kemppi ArcFeed voltage
sensing wire feed unit, or FastMig series MSF and MXF wire feeding units. When using MSF or
MXF wire feed units, connect the unit as described in picture on page 6, and select the MXF
mode from the AS panel. For further information see MSF or MXF manuals.

When you use the ArcFeed voltage sensing wire feed unit, you must select either CC or CV
(Constant Current or Constant Voltage) mode from the AS control panel. Ensure that the
ArcFeed control panel has been set to correspond with the power source control panel. For
example if power source is set to CC mode, the ArcFeed should also be set to CC mode. In CV
mode FastMig AS has two welding programs for ArcFeed welding: one for self shielding ller
wires and the other for standard cored and solid ller wires. The welding program can be
changed in SETUP function.

It is possible to connect MSF or MXF and ArcFeed feeders to FastMig KMS AS power source
simultaneously. For example, this can be an ecient combination when using Kemppi

8

FastMig KMS 400 AS

WiseRoot process for root pass welding and then completing hot pass and ller runs with
ArcFeed system using self-shielded ller wire.

MMA welding

FastMig KMS AS is also suitable for MMA welding with basic or rutile electrodes. MMA welding
works with CC (Constant current) mode set from the AS power source panel.

NOTE! In CC/MMA mode FastMig KMS AS has two welding programs: one for ArcFeed CC welding

and the other for MMA welding. The desired welding program can be chosen from the KMS AS
‘SETUP’ function.

TIG welding

By connecting MasterTig LT 250 to FastMig M with AS panel, TIG welding can be done. You
must select either CC or CV (Constant Current or Constant Voltage) mode from the AS control
panel.

2.8 Setup functions

With a long press of the SETUP button you can move to the Setup menu

Start Power
Device address

Welding program CC/MMA
Welding program CV
Restore factory settings

Remote control

StA -9 ... +9 0 Strength of start pulse
Add 3 or 6 6 System bus address. Each device in same system

must have dierent address.
Pro Stl, FEE StI is for MMA welding FEE is for ArcFeed
Pro Std, InS InS is for innershield wires Std for other wires
FAC OFF, PAn, ALL OFF Restores factory settings, when PAn or ALL is

selected
rc OFF, on OFF Manual control / remote control unit selection

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS

3.1 Main switch I/O

When you turn the switch into I-position, pilot lamp H11 on the front face is illuminated and
the machine is ready for use.

NOTE! Always turn the machine on and o with the mains switch, never use the mains plugs as a

switch.

3.2 Pilot lamps

The pilot lamps of the machine report the electric operation:
The green pilot lamp H11 when lit indicates that the machine is on and ready for use and it is

connected to the mains supply with the main switch in the I-position.
H12 indicates when lit that the thermal protection of the machine has been activated due to

over heating. The cooling fan will continue to run and cool the machine down and when the
lamp is o the machine is ready to weld.

EN

3.3 Operation of cooling fan

In FastMig KMS 400 AS power source there is two simultaneously operating fans.

• The fan is started for a moment when main switch is placed into position I.

• The fan will start during welding as the machine heats up and it will run for 1 to 10

minutes after the welding has stopped.

© Kemppi Oy / 1515

9

EN

4. BASIC TROUBLESHOOTING

NOTE! The problems listed and the possible causes are not denitive, but serve to suggest some

standard and typical situations that may present during normal environmental use when using
the MIG/MAG process with FastMig.

Problem Check the following

Machine won’t work? • Check mains plug is connected

• Check mains power distribution is switched on

• Check the mains fuse and or circuit breaker

• Check power source 0/I switch is ON

• Check interconnection cable set and connectors between the power source and

wire feed unit are correctly fastened. See the manual schematic

• Check earth return lead is connected

• Check function panels are switched on – Orange buttons top left, long press.

Dirty, poor quality weld? • Check shielding gas supply

• Check and set gas ow rate

• Check gas type for application

• Check gun/electrode polarity. Example: Fe solid ller wire: Earth return should be

connected to the – pole, wire feed unit to the + pole connector

• Check correct welding curve selected

• Check correct Channel (job) number selected on PF65 function panel

• Check power supply – Phase down?

Variable welding performance? • Check wire feed mechanism is correctly adjusted

• Check correct drive rolls are tted

• Check wire spool overrun tension is correctly adjusted

• Check gun liner is not blocked. Replace if necessary

• Check correct gun liner is tted for the ller wire size and type

• Check contact tip for size, type and wear

• Check gun is not over heating in application

• Check cable connections and earth return clamp

• Check welding parameter settings.

Filler wire won’t feed? • Check wire feed mechanism. Pressure arms are closed? Close and adjust

• Check welding gun switch function.

• Check euro gun collar is correctly fastened to euro block

• Check gun liner is not blocked

• Check contact tip, size, type, wear

• Check and try alternative gun.

High spatter volume? • Check welding parameter values

• Check inductance/Dynamics values

• •Checkcablecompensationvalueiflongcablesaretted

• Check gas type and ow

• Check welding polarity – cable connections

• Check ller material selection

• Check correct welding curve selected

• Check correct Channel (job) number selection

• Check ller wire delivery system

• Check power supply – 3 x phase present?

NOTE! Many of these checks may be carried out by the operator. However certain checks relating to

mains power must be completed by an authorised trained electrician.

10

FastMig KMS 400 AS

5. MAINTENANCE

When considering and planning routine maintenance, please consider the frequency of
machine use and the working environment.

Correct operation of the machine and regular maintenance will help you avoid unnecessary
downtime and equipment failure.

NOTE! Disconnect the machine from the mains before handling the electrical cables.

5.1 Daily maintenance

• Check the overall condition of the welding gun. Remove welding spatter from the
contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original
Kemppi spare parts.

• Check the condition and connection of the welding circuit components: welding gun,
earth return cable and clamp, sockets and connectors.

• Check the condition of the feed rolls, needle bearings and shafts. Clean and lubricate
bearings and shafts with a small quantity of light machine oil if necessary. Assemble,
adjust and test function.

5.2 Periodic maintenance

NOTE! Periodic maintenance should only be carried out by a suitably qualied person. Disconnect

the plug of the machine from the mains socket and wait approx.2 minutes (capacitor charge)
before removing the cover plate.

Check at least every half year:

• Electric connectors of the machine – clean any oxidized parts and tighten loose
connections.

NOTE! You must know the correct tension torques values before starting the reparation of the loose

joints.

Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and vacuum
cleaner. Also clean the ventilation net behind the front grill.

Do not use compressed air, there is a risk that the dirt will compact even more tightly into
gaps of cooling proles.

Do not use pressure washing devices.
Only an authorized trained electrician should carry out repairs to Kemppi machines.

5.3 Service shop maintenance

Kemppi Service Workshops complete maintenance according to their Kemppi service
agreement.

The major points in the maintenance procedure are listed as follows:

• Cleaning of the machine

• Checking and maintenance of the welding tools

• Checking of connectors, switches and potentiometers

• Checking of electric connections

• Checking of mains cable and plug

• Damaged parts or parts in bad condition are replaced by new ones

• Maintenance testing.

• Operation and performance values of the machine are checked, and when necessary

adjusted by means of software and test equipment.

EN

© Kemppi Oy / 1515

11

EN

6. OPERATION DISTURBANCES

Should you experience a malfunction from your machine, please consult the basic
troubleshooting text above rst, and complete some basic checks. If the machine malfunction
cannot be corrected with these measures, contact your KEMPPI maintenance service
workshop.

6.1 Operation of the overload protection

Yellow thermal protection lamp is lit when the thermostat is operating due to loading beyond
the stated duty cycle.

The thermostat will operate, if machine is continuously loaded over rated values or cooling air
circulation is blocked.

Internal fans will cool the machine, and when the pilot lamp is not lit the machine is
automatically ready for welding.

6.2 Control fuses

Fuse, 6.3 A delayed, on the rear wall of machine provides protection for auxiliary devices.

NOTE! Use same type and rating of fuse which is marked beside the fuse adapter. Damage caused

by a wrong type fuse is not covered by the guarantee.

6.3 Under- and overvoltages in the mains supply

Primary circuits of the machine are protected against sudden, transient overvoltages. The
machine is designed to withstand 3 x 440 V voltage continuously (see technical data). Ensure
that voltage is kept within this admissible limit, especially when the mains supply is provided
by a combustion engine generator. If the mains has under voltage (under approx. 300 V) or
overvoltage (over approx. 480 V) machine control stops operation automatically.

6.4 Loss of a phase in the mains supply

Loss of a main power phase causes noticeably poor welding properties. In some cases the
machine won't start at all. Loss of a phase can be due to following:

• Blowing of mains supply fuse

• Defective mains cable

• Bad connection of mains connection cable on terminal block or plug of machine.

7. DISPOSAL OF THE MACHINE

Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic

equipment, and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and taken to an appropriate
environmentally responsible recycling facility.

The owner of the equipment is obliged to deliver a decommissioned unit to a regional
collection centre, per the instructions of local authorities or a Kemppi representative. By
applying this European Directive you will improve the environment and human health.

12

FastMig KMS 400 AS

8. ORDERING NUMBERS

FastMig KMS 400 AS
Wire feeders
ArcFeed 200
ArcFeed 300
ArcFeed 300P
MXF 65
MXF 67
MXF 63
MXF 65
MXF 67
MXF 63
Panels for MSF and MXF feeders
SF 51
SF 52W
SF 53W
SF 54
Accessories
Return current cable
Return current cable
Cable for MMA welding
Cable for MMA welding
Remote controlled interconnecting cable
Cooling unit Fastcool 10
Transport unit PM 500
Gun holder GH 30

6054001

6120200
6120300
6120310
6152100EL
6152200EL
6152300EL
6152100
6152200
6152300

6085100
6085200W
6085300W
6085400

5 m, 50 mm² 6184511
5 m, 70 mm² 6184711
5 m, 50 mm² 6184501
5 m, 70 mm² 6184701
10 m 6185481

6068100
6185291
6256030

EN

© Kemppi Oy / 1515

13

EN

9. TECHNICAL DATA

FastMig KMS 400 AS
Connection voltage

3~, 50/60 Hz 400 V -15 %...+20 %

Rated power

60 ED ­80 % ED 19.5 kVA
100 % ED 18.5 kVA

Connection cable/fuse delayed

H07RN-F 4G6 (5 m)
Fuse (delayed) 35 A

Load capacity 40 °C

60 % ED ­80 % ED 400 A
100 % ED 380 A

Welding current and voltage range

MMA 10 A ... 400 A
MIG 10 V ... 39 V

Max. welding voltage
Open circuit voltage
Open circuit power
Efficiency at max. current
Power factor at max. current
Operating temperature range
Storage temperature range
Degree of protection
EMC class
Minimun short circuit power Ssc of supply network*
External dimensions (LxWxH)
Weight
Voltage supply for auxiliary devices
X14, X15
Voltage supply for cooling unit

46 V
50 V
25 W
87 %

0.9

-20 ... +40 ºC

-40 ... +60 ºC
IP23S
A

4.7 MVA
590x230x430 mm
35 kg
50 V DC
fuse 6.3 A delayed
1~ 400 V AC and 24 V DC

14

* See paragraph 3.1.

FastMig KMS 400 AS

KEMPPI OY

Kempinkatu 1
PL 13
FIN-15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
[e-mail]
www.kemppi.com

Kotimaan myynti:

Tel [phone]
Telefax [phone]
myynti.@kemppi.com

KEMPPI SVERIGE AB

Box 717
S-194 27 UPPLANDS VÄSBY
SVERIGE
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI NORGE A/S

Postboks 2151, Postterminalen
N-3103 TØNSBERG
NORGE
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI DANMARK A/S

Literbuen 11
DK-2740 SKOVLUNDE
DANMARK
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI BENELUX B.V.

NL-4801 EA BREDA
NEDERLAND
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI (UK) LTD

Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK44 3WH
UNITED KINGDOM
Tel [phone]

Telefax [phone]
[e-mail]

KEMPPI FRANCE S.A.S.

65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI GMBH

Perchstetten 10
D-35428 LANGGÖNS
DEUTSCHLAND
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI SPÓŁKA Z O.O.

Ul. Borzymowska 32
03-565 WARSZAWA
POLAND
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI AUSTRALIA PTY LTD

13 Cullen Place
P.O. Box 5256, Greystanes NSW 2145
SMITHFIELD NSW 2164
AUSTRALIA
Tel. [phone]
Telefax [phone]
[e-mail]

OOO KEMPPI

Polkovaya str. 1, Building 6
127018 MOSCOW
RUSSIA
Tel [phone]
Telefax [phone]
[e-mail]

ООО КЕМППИ

ул. Полковая 1, строение 6
127018 Москва
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI, TRADING (BEIJING) COMPANY LTD

Unit 105, 1/F, Building #1,
No. 26 Xihuan South Rd.,
Beijing Economic-Technological Development
Area (BDA),
100176 BEIJING
CHINA
Tel [phone]
[phone]
Telefax [phone]
[e-mail]

肯倍贸易（北京）有限公司
中国北京经济技术开发区
西环南路26号
1号楼1层105室(100176)
电话： [phone]/1282
传真： [phone]

[e-mail]

KEMPPI INDIA PVT LTD

LAKSHMI TOWERS
New No. 2/770,
First Main Road,
Kazura Garden,
Neelankarai,
CHENNAI - 600 041
TAMIL NADU
Tel [phone]
Telefax [phone]
[e-mail]

KEMPPI WELDING SOLUTIONS SDN BHD

No 12A, Jalan TP5A,
Taman Perindustrian UEP,
47600 Subang Jaya,
SELANGOR, MALAYSIA
Tel [phone]
Telefax [phone]
[e-mail]

www.kemppi.com

1905320

1515